Friction fit composite column

ABSTRACT

A composite assembly includes a series of elongated layers joined lengthwise thereof. At least two of the elongated layers each have an upper elongated portion and a lower elongated portion secured together in an end-to-end relationship at a joint therebetween by a connector arrangement. The upper elongated portion is constructed of a wood material, and the lower elongated portion is constructed of a non-wood material. The lower elongated portion may have a reinforcing rod therein.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. Ser. No. 15/363,576filed Nov. 29, 2016, now U.S. Pat. No. 9,719,257, which applicationpublished on Mar. 16, 2017 as U.S. 2017/0073972, which applicationrelates to and claims priority to U.S. Provisional Patent ApplicationSer. No. 62/405,623 filed on Oct. 7, 2016 and is a Continuation-in-Partof and claims priority to U.S. patent application Ser. No. 14/962,022filed Dec. 8, 2015, now U.S. Pat. No. 9,528,265, grant date Dec. 27,2016, which is a Continuation-in-Part of U.S. patent application Ser.No. 14/562,054 filed Dec. 5, 2014, now U.S. Pat. No. 9,234,350, grantdate Jan. 12, 2016, which claims priority to U.S. Provisional PatentApplication Ser. No. 61/912,681 filed Dec. 6, 2013, all of which areincorporated herein in their entireties.

FIELD OF THE DISCLOSURE

The present disclosure relates to a composite assembly for use in theconstruction industry. More specifically, the present disclosure relatesto a friction fit composite column base for use in a structuralassembly.

BACKGROUND

In the construction of buildings, outdoor structures or the like, it isoften desirable to utilize a beam or column which includes a pluralityof boards, rather than an integral post made from a single piece ofbuilding material such as wood. Many embodiments of composite assembliesuse one or more connectors to connect the plurality of component boardsinto the composite assembly. The composite assembly made from aplurality of boards can serve as a less expensive substitute forintegral posts made from a single piece of wood, which can be quiteexpensive. It is not uncommon for building materials to increaseexponentially in cost for every increase in length or width of thebuilding material piece.

It is known to provide a composite assembly comprised of a series ofelongated layers secured together lengthwise thereof with each layerincluding an upper elongated support member joined to a lower elongatedground-engaging member at a joint by a connector device. In such acomposite assembly, the upper elongated member is normally constructedof a non-treated wood, and the lower elongated member is typicallyfabricated of a treated wood. Such treated wood is infused with achemical, such as chromated copper arsenate (CCA), to prevent thenatural process of decay of the ground-engaging wood. While such acomposite assembly is acceptable in commercial building application, theEnvironmental Protection Agency (EPA) has banned the use of wood as usedin the ground-engaging lower portion of the composite assembly for mostresidential use.

BRIEF DISCLOSURE

Therefore, Applicant has developed a composite assembly which iscompliant with EPA regulations for use in residential application, andwhich is disclosed herein. The composite assembly is adapted for use asa support column in a building structure, and is comprised of a seriesof layers joined together lengthwise thereof. At least two of theelongated layers each include an upper elongated portion and a lowerelongated portion secured together in an end-to-end relationship at ajoint therebetween by a connector arrangement. The upper elongatedportion is constructed of a first material comprised of wood, and thelower elongated portion is constructed of a second material comprised ofa material other than wood, such as plastic.

In one exemplary embodiment, the lower elongated portions are embodiedin separate, integrally formed segments. In another exemplaryembodiment, the lower elongated portions are jointly formed together ina unit.

In another exemplary embodiment, the composite assembly is adapted foruse as a support column in a building structure, and is comprised of aseries of layers joined together lengthwise thereof. At least two of theelongated layers each include an upper elongated portion secured to aunitary lower assembly in an end-to-end relationship at a jointtherebetween by a connector arrangement. The upper elongated portion isconstructed of a first material comprised of wood, and the unitary lowerassembly is constructed of a second material comprised of a materialother than wood, such as plastic. Each joint between the upper elongatedportion and the unitary lower assembly is staggered at different heightsrelative to one another.

In yet another embodiment, a composite assembly adapted for use as avertical support column in a building structure includes at least twoelongated layers joined together lengthwise thereof, including an upperelongated portion and a unitary lower assembly joined in an end-to-endrelationship by a connector arrangement. The unitary lower assemblyincludes at least one reinforcing rod. The upper elongated portion isconstructed of a first material comprised of wood, and the unitary lowerassembly is constructed of a second material other than wood, such asplastic.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a dual sided connectorused in a composite assembly;

FIG. 2 is a top view of an embodiment of the dual sided connector;

FIG. 3 is a side view of an embodiment of the dual sided connector;

FIG. 4 is a close up view of an embodiment of a tooth pair of the dualsided connector;

FIG. 5 is a side view of a tooth pair of the dual sided connector;

FIG. 6 is a side view of a tooth pair of the dual sided connector;

FIG. 7 depicts a composite assembly comprising a dual sided connector;

FIG. 8 is a cross sectional view of a composite assembly comprising adual sided connector;

FIG. 9 is a front view of one embodiment of a composite assembly inaccordance with the present disclosure;

FIG. 10 is a front view of another embodiment of a composite assembly inaccordance with the present disclosure.

FIG. 11 is a broken into front view of yet another embodiment of acomposite assembly in accordance with the present disclosure;

FIG. 12 is an enlarged detail view taken on line 12-12 of FIG. 11;

FIG. 13 is a side view of a central elongated region of the compositeassembly shown in FIGS. 11 and 12;

FIG. 14 is an enlarged sectional view taken on line 14-14 of FIG. 11;

FIG. 15 is a front view of a unitary lower assembly used in thecomposite assembly of FIG. 11;

FIG. 16 is a front view of an additional embodiment of a unitary lowerassembly;

FIG. 17 is an enlarged detail view taken along line 17-17 of FIG. 16;

FIG. 18 is an enlarged sectional view taken along line 18-18 of FIG. 16;and

FIG. 19 is an enlarged sectional view taken along line 19-19 of FIG. 16.

FIG. 20 is a front view of another embodiment of a unitary lowerassembly.

FIG. 21 is a perspective view of another embodiment of a unitary lowerassembly.

FIG. 22 is a front view of one embodiment of a composite assembly havinga unitary lower assembly in accordance with the present disclosure.

FIG. 23 diagrammatically depicts a composite assembly installed within ahole in the ground.

FIG. 24 depicts an exemplary embodiment of a lower assembly.

FIG. 25 is a perspective view of a first embodiment of a connectionbracket.

FIG. 26 is a perspective view of a second embodiment of a connectionbracket.

FIG. 27 depicts an exemplary embodiment of a connection plate.

FIGS. 28A and 28B depict an exemplary embodiment of a bottom plate.

DETAILED DESCRIPTION

Dual sided connectors and composite assemblies including dual sidedconnectors are disclosed herein. The dual sided connectors can be usedto interconnect a member of building material such as wood or woodcomposite timbers or boards in order to produce beams, columns, headers,trusses, or any other composite assemblies for use in the constructionof buildings or the like. Embodiments of the dual sided connector caninclude a base plate with a plurality of teeth extending outwardly fromthe base plate. The dual sided connector can be disposed between layersor plies of building material so that it bridges an inner portion of thebuilding material. When this assembly is compressed together, the teethengage the building material and are embedded in the building material.Thus, building material members are spliced together to form thecomposite assembly.

Composite assemblies formed using connector plates are economicalreplacements for the use of integral or one piece wooden beams orcolumns in building construction. The ability of a composite assembly tobe formed of smaller, and therefore cheaper, building material stockallows for the creation of a composite assembly of similar dimensionsand strength of an integral beam, at a fraction of the cost. Variouspatterns and orientations for the teeth of the connectors are known andtypically include teeth that enter a wooden component member parallel tothe wood grain or perpendicular to the wood grain. However, it has beendetermined that these tooth alignments are undesirable, and an improvedtooth arrangement is needed. Connector teeth that enter the woodparallel to the wood grain promote splitting of the wood along the woodgrain, while teeth that enter the wood perpendicular to the wood grainare often flattened upon insertion into the wood and therefore showreduced ability to be secured into the wood.

FIG. 1 depicts an embodiment of a dual sided connector 10. The dualsided connector 10 comprises a base plate 12. The base plate 12 may beof a galvanized steel; however, the type of material for the base plate12 should not herein be limited to galvanized steel, but may alsoinclude any other suitable material that would be recognized by oneskilled in the art. A plurality of teeth including a first tooth 18 anda second tooth 20 extend outwardly from the base plate 12. The firsttooth 18 and the second tooth 20 form a tooth pair 22.

Referring to FIG. 3, the base plate 12 further includes a first surface24 and a second surface 26. The first tooth 18 and second tooth 20 forma tooth pair 22 that extends outwardly from the first surface 24 of thebase plate 12. A third tooth 28 and a fourth tooth 30 form a tooth pair32 that extends outwardly from the second surface 26 of the base plate12. Thus, tooth pair 22 extends in an opposite direction from the baseplate 12 than tooth pair 32 extends from the base plate 12.

In an embodiment, the outwardly extending teeth may be formed by diecutting the teeth from the material of base plate 12 through the use ofa punching mechanism using a die to cut the teeth from the base plate12. In these embodiments, the die may be formed to produce twistedteeth, as will be disclosed in greater detail herein, as the die passesthrough the base plate 12. The punching mechanism may be arranged suchthat a separate die or set of dies is used to punch the teeth extendingin each direction from the base plate 12. These teeth may be punchedsimultaneously or separately. As a result of the die cutting, someembodiments may include an opening 34 formed in the base plate 12 (asdepicted in FIGS. 1 and 2) where the material for each of the teeth wasremoved. Each tooth pair 22 is cut by a single die cut resulting in asingle opening 34 between the first tooth 18 and the second tooth 20 ofthe tooth pair 22.

It is understood that while for the sake of simplicity, first surface24, first tooth 18, second tooth 20, and tooth pair 22 are described infurther detail herein, the description is similarly applicable to thesecond surface 26, third tooth 28, fourth tooth 30, and tooth pair 32,projecting from the opposite side of base plate 12.

Referring to the embodiment of the dual sided connector 10 depicted inFIGS. 5 and 6, both the first tooth 18 and the second tooth 20 of toothpair 22 project outwardly from the base plate 12 in the same directionfrom the first surface 24. The first tooth 18 and second tooth 20 extendgenerally parallel to each other and generally perpendicular to the baseplate 12. The first tooth 18 and second tooth 20 are trapezoidal inshape with a base end 36 connected to the base plate 12 and an outwardlyextending end 38 away from the first surface 24. The outwardly extendingend 38 of the first tooth 18 terminates in a tip 40. The outwardlyextending end 38 of the second tooth 20 terminates in a tip 42. The tip40 and tip 42 may simply come to points, but also may be manufactured soas to be chiseled in profile. The tip 40 of the first tooth 18 matchesin height, the tip 42 of the second tooth 20.

The tip 42 of the second tooth 20 is offset from the tip 40 of the firsttooth 18, as seen in FIG. 6. Teeth 18 and 20 each have a vertical axis52 as will be described in further detail herein. The tips 40 and 42 maybe offset from each other at opposite sides of the vertical axis 52 oftheir respective tooth. Thus tip 40 is offset to one side of verticalaxis 52 and tip 42 is offset to the other side of vertical axis 52. Theoffset of tips 40 and 42 of this embodiment provide particularadvantages when the dual sided connector 10 is used to join two or moremembers of building material. One advantage is that the offset nature oftip 40 and tip 42 help to evenly balance each building material memberon the connector 10 and promote even insertion of the teeth (18, 20)into the building material members. Additionally, the tips (40, 42)reduce the force necessary to penetrate the building material member andhelp to reduce any instances of splitting in the building materialmembers as a result of the insertion of teeth into the building materialmembers.

The offset tips 40 and 42 provide an additional advantage inmanufacturing the dual sided connector 10. In this embodiment, a dieused to cut the tooth pair 22 can cut both the first tooth 18 and thesecond tooth 20 at the same time as the offset tips (40, 42) of thefirst and second teeth (18, 20) interlace in the die pattern. Thus onlya single die cut is needed to cut both the first tooth 18 and the secondtooth 20 including the tips (40, 42) of the teeth. Therefore, in someembodiments, the dual sided connector 10 may have the additional benefitof providing the presently disclosed features with a simplifiedmanufacturing process to make the dual sided connector 10.

Still referring to FIGS. 5 and 6, the first tooth 18 and the secondtooth 20 are oriented in the tooth pair 22 such that each tooth has anelongated profile 44 and a narrow profile 46. In the tooth pair 22, theelongated profiles 44 of the teeth are parallel and face each other. Theelongated profiles 44 of the teeth promote gripping of the buildingmaterial upon insertion and the narrow profiles 46 of the tooth promoteinsertion of the tooth into the building material and reduced splittingof the building material.

Referring to FIGS. 1 and 2, the dual sided connector 10 is arranged witha plurality of tooth pairs 22 oriented in a series of rows 48. The rows48 are aligned on the base plate 12 perpendicular to the elongatedprofile 44 (See FIG. 6) of the teeth of the tooth pair 22. The pluralityof tooth pairs 22 in each of the rows 48 all extend outwardly from thefirst surface 24 of the base plate 12 in the same direction. The dualsided connector plate 10 is further arranged with a plurality of rows 50comprising tooth pairs 32 extending outwardly from the second surface 26of the base plate 12 and in the opposite direction from tooth pairs 22.Rows 50 are aligned on the base plate 12 in an alternating fashion withrows 48 alternatingly extending from the base plate 12 in the oppositedirection. The alternating rows 48 and 50 of outwardly extending toothpairs 22 and tooth pairs 32 in opposite directions promote an evendistribution of the tooth pairs (22, 32) extending from the firstsurface 24 and the second surface 26 of the base plate 12. Therefore,the teeth in rows 48 extend from the base plate 12 in one direction andthe teeth in rows 50 extend from the base plate 12 in the oppositedirection. Some embodiments of the dual sided connector 10 may featurerows 48 and 50 in which the tooth pairs (22, 32) in alternating rows(48,50) are offset, as depicted in FIGS. 1 and 2. The offset of opposingtooth pairs further improve the uniformity of the distribution of theteeth in the dual sided connector 10 and may promote additional supportand structural strength within the base plate 12.

Now referring to FIGS. 4-6, as mentioned previously, the first tooth 18and the second tooth 20 of the tooth pair 22 each comprise a verticalaxis 52 perpendicular to the base plate 12. The first tooth 18 and thesecond tooth 20 are twisted about this axis. Similar or matching twistsmay be placed in both the first tooth 18 and the second tooth 20 of thetooth pair 22. The twist angle 54 is generally between an angle of zeroand 45 degrees from normal. The twist angle 54 may be any angle withinthis range. In one embodiment, the angle is 20 degrees or less. Inanother embodiment, the angle is between 10 and 15 degrees. In anotherembodiment, the angle may be between zero and 10 degrees. In a furtherembodiment, the angle may be three degrees. The twists in the teeth (18,20) may be clockwise or counter clockwise, and may all be in the samedirection for all of the teeth. In alternative embodiments, the twistsin the teeth (18, 20) may be different for different individual teeth,or may be coordinated between tooth pairs 22, rows 48, 50 of toothpairs, or on each side of the dual sided connector 10. It should beunderstood that in embodiments wherein the tooth pair 22 is cut by adie, the die may be modified in order to produce the desired angle ofthe twist, or the orientation of the twist for the teeth in the toothpair 22.

The feature of the twisted teeth of the dual sided connector 10 provideadvantages in use and implementation of the dual sided connector 10 overprevious connector designs and implementations as will be described infurther detail herein.

Referring to FIGS. 7 and 8, the dual sided connector 10 may be used toconstruct a composite assembly 56 such as a beam, post, column, truss,or the like. The composite assembly 56 may be formed from a plurality ofelongated wood boards 58. In the embodiment disclosed in further detailherein the composite assembly 56 comprises a plurality of wood boards58; however, it is understood that other building material memberscomprising not only wood and wood composite boards, but engineeredboards, synthetic composite materials, or any other suitable buildingmaterials as recognized by one skilled in the art may be used. The woodboards 58 may be of varying lengths, but each has face 60 on oppositesides of the board 58 and each board 58 terminates in an end 62.

Wood boards 58 are disposed in an end-to-end relationship wherein theend 62 of one board 58 abuts an end 62 of a second board 58. The ends 62of the wood boards 58 meet to form a joint 68. The one or more woodboards 58 aligned in the end-to-end relationship form a first layer 64of the composite assembly 56. The composite assembly 56 may comprise aplurality of layers, depicted here as a second layer 72 and a thirdlayer 74. Each of the layers (64, 72, 74) are made up of at least onewood board 58 and it should be understood that the composite assembly 56may be made from any number of layers, from two or more.

The first layer 64 and the second layer 72 are aligned in a face-to-facerelationship wherein the faces 60 of the wood boards 58 in the firstlayer 64 are arranged to contact the faces 60 of one or more wood boards58 of the second layer 72. At least one of the layers, such as firstlayer 64, includes a plurality of wood boards 58. The joint 68 betweenthe wood boards 58 of the layer 64 is secured using one side of the dualsided connector 10 as disclosed herein to connect the wood board 58 tothe other wood board 58 across the joint 68.

In implementation, the composite assembly 56 is formed by aligning adual sided connector 10 across the joint 68 of two boards 58 in thefirst layer 64. In one embodiment, the dual sided connector 10 isaligned so that half of the tooth pairs 32 on the second surface 26 ofthe dual sided connector 10 are arranged over one of the wood boards 58of the first layer 64 and the other half of the tooth pairs 32 on thesecond surface 26 of the dual sided connector 10 are arranged over theother wood board 58 of the first layer 64. Thus, the dual sidedconnector 10 is evenly arranged over the joint 68.

The second layer 72 includes at least one wood board 58 and is arrangedover the top of the dual sided connector 10. A single wood board 58 ofthe second layer 72 is placed in contact with the teeth extending fromthe first surface 24 of the dual sided connector 10. The compositeassembly 56 is arranged in this manner so that the dual sided connector10 does not cover a joint 68 between two boards 58 in both the firstlayer 64 and the second layer 72. The staggering of the joints 68 acrossthe layers (64, 72, 74) promotes strength in the fully constructedcomposite assembly 56. Each staggered joint 68 of one layer is matchedwith a face of a single wood board 58 of the next layer. Therefore, eachdual sided connector 10 of the composite assembly 56 attaches threeboards together.

The wood boards 58 are constructed such that a wood grain 70 runsgenerally along the length of each of the boards 58. In a further aspectof the disclosure, the dual sided connector 10 is aligned over the joint68 between the boards 58 such that the dual sided connector 10 is squarewith each of the boards 58 and evenly disposed over the boards 58 of thejoint 68. Furthermore, the dual sided connector 10 is arranged with theelongated profile 44 of each of the teeth of the dual sided connectoraligned generally parallel with the wood grain 70 of the boards 58. Asimilar alignment exists between the dual sided connector 10 and thewood board 58 of the second layer 72, aligned in face-to-facerelationship with the first layer 64. Therefore, the elongated profile44 of the teeth of the dual sided connector 10 is also aligned generallyparallel with the wood grain 70 of the board 58 of the second layer 72.

While it is understood that the teeth of the dual sided connector 10 aretwisted as disclosed above and the grain of the wood boards 58 isgenerally variable, and therefore the twisted teeth will generally notbe perfectly parallel with the grain 70 of the wood board 58, becausethe twist angle 54 of each of the teeth is less than 45 degrees and thewood grain 70 runs generally parallel to the length of each of theboards 58, if the dual sided connector 10 is square with the board 58,there will be a preferred orientation in which the elongated profile 44of the teeth of the dual sided connector 10 are more generally parallelwith the wood grain 70 and an alternative, less favored orientation inwhich the elongated profile 44 of the teeth of the dual sided connector10 are more generally perpendicular to the wood grain 70 of the boards58. The general alignment of the elongated profile 44 of each of theteeth of the dual sided connector with the wood grain 70 of the boards58 improves the resulting penetration of the teeth into the wood boards58 as will be described in further detail herein.

It is understood that in alternative embodiments, the dual sidedconnector 10 may be aligned such that the elongated profile 44 at thebase of the teeth is generally parallel with the wood grain 70.Alternatively still, the elongated profile 44 of each of the teeth atthe tip (40, 42) may be aligned generally parallel with the wood grain70.

Once the wood boards 58 and the dual sided connector 10 have beenarranged as disclosed, a compressive force is applied to the wood boards58 of the composite assembly 56. This presses the dual sided connector10 into the wood boards 58 of both of the layers. The alignment of theteeth of the dual sided connector 10 in general alignment with the woodgrain 70 of the wood boards 58 as well as the tips (40, 42) of the teethof the dual sided connector 10 and the offset orientation of the tips(40, 42) of the teeth (18, 20) in each tooth pair 22 of the dual sidedconnector 10 promote the penetration of the teeth into the wood boards58. This allows for the dual sided connector 10 to embed into the woodboards upon compression of the composite assembly 56 such that the dualsided connector 10 is not visible in the completed composite assembly56. Rather, the teeth and the base plate 12 of the dual sided connector10 are embedded between the layers (64, 72, 74) of the wood boards 58.The twisting of each of the teeth of the dual sided connector 10 helpsto limit any splitting of the wood boards 58 along the grain of the wood70 as the teeth enter the wood offset from parallel with the wood grain70. Yet, the twist angle is acute enough such that the teeth do notenter the wood substantially perpendicular to the wood grain 70 andtherefore desirable penetration is achieved into the wood boards 58. Thedual sided connector 10 exhibits an improved gripping ability as thetwisted teeth are more resistant to loosening over time than straightteeth

Embodiments of the composite assembly 56 may include multiple layers tothe composite assembly 56, which are represented by layer 74, in orderto create the desired width of the composite assembly 56. In theseembodiments, one or more additional dual sided connectors 10 may be usedto connect the layers of the composite assembly 56. In some embodiments,the outside layer (i.e. second layer 72) on either side of the compositeassembly 56 comprises a single integral board running the length of thecomposite assembly 56. One or more interior layers (i.e. first layer 64or third layer 74) may comprise a plurality of boards 58 in each layerextending to the desired total length of the composite assembly 56. Thispresents the advantage of reducing the cost of the composite assembly 56by using shorter, and therefore less expensive boards 58 on the interiorof the composite assembly 56, while the aesthetics of the compositeassembly 56 are promoted through the continuous outside facing boards.This eliminates visible joints 68 in the faces of the composite assembly56 and promotes the illusion that the composite assembly 56 is a singlepiece of material.

The composite assembly 56 therefore presents the advantages of having animproved aesthetic appearance as the improved penetration of the dualsided connectors 10 hide the dual sided connectors 10 in the interior ofthe composite assembly 56 by embedding the dual sided connectors 10 intothe boards 58 of the composite assembly 56. Also, the orientation of thetwisted teeth of the dual sided connector reduces the likelihood ofsplitting the boards 58 of the composite assembly 56 and thus moreconsistently produces an aesthetically pleasing composite assembly 56that is free of splits, cracks, or other defects due to the connectorplates. The composite assembly 56 further exhibits the advantage ofbeing stronger than previous composite assemblies as the improvedpenetration of the teeth and the twisted orientation of the teethprovide a tighter hold between the dual sided connector 10 and theboards 58 of the composite assembly 56. Additionally, the reducedsplitting experienced with the disclosed dual sided connector furtherimproves the overall strength and integrity of the composite assembly 56as splits or other flaws may create weak spots within the compositeassembly 56 that are aggravated in load bearing use.

It should be understood from the disclosure herein that manymodifications as would be recognized by one skilled in the art may bemade to the embodiments disclosed herein and will be considered to bewithin the scope of this disclosure. In this respect, the dual sidedconnector as disclosed herein may be constructed to any dimension as oneskilled in the art may deem suitable for the desired implementation anduse in constructing a composite assembly. In embodiments wherein thedual sided connector is to be embedded within the composite assembly andthus not visible in the finished composite assembly, it is understoodthat the dimensions of the dual sided connector would include those thatare smaller than the dimensions of the wood boards of which thecomposite assembly is comprised. It is further understood that thecomposite assembly may include a plurality of layers of wood boardsconnected by a plurality of dual sided connectors in order to form acomposite assembly having greater dimensions than those of the singlewooden boards.

The present disclosure contemplates a composite assembly 76 such as maybe used as a vertical support column in a residential buildingstructure.

Referring to FIGS. 9 and 10, the composite assembly 76 is comprised of aseries or plurality of opposing elongated layers 78, 80, 82 joinedtogether lengthwise thereof. Each of the layers 78, 80, 82 includes anupper elongated portion in the form of an elongated member 84, and alower elongated portion in the form of an elongated member 86. The upperand lower elongated portions 84, 86 are secured together in anend-to-end relationship at joints 88 by connector arrangements orconnectors 10 as previously described above. Top ends of the upperelongated portions 84 are typically used for supporting a superstructureof a building structure. Bottom ends of the lower elongated portions 86are embedded securely beneath a ground surface G. Each of the elongatedlayers 78, 80, 82 are joined together along opposed interior faces bythe connectors 10 at the joints 88 as well as at other locations spacedapart from and above the joints 88.

In accordance with the present disclosure, the upper elongated portions84 are constructed of a first material comprised of wood. In contrast,the lower elongated portions 86 are constructed of a second materialcomprised of a material other than wood. One example of a non-woodmaterial to be used is plastic; however, it should be understood thatthe second material is not limited exclusively to plastic, and that useof other non-wood materials in the lower elongated portions 86 iscontemplated as desired.

In the embodiments shown in FIG. 9, the upper elongated portions 84 forman upper assembly 92 constructed of single elongated member of wood,exemplarily untreated wood. A lower assembly 90 is constructed of thelower elongated portions 86 which are single members of a non-woodmaterial. It should be understood that the elongated portions 84, 86 mayalternatively be constructed of multiple elongated members joinedtogether suitably by connectors 10. For example, upper elongatedportions 84 may include more than one elongated member while lowerelongated portions 86 may remain fabricated of single elongated members.

As described above, in the embodiment of FIG. 9, the lower assembly 90is formed of elongated portions 86 embodied in individual elongatedmembers formed separately and individually from one another. In theembodiment of FIG. 10, the lower assembly 90 is formed together as asingle unitary structure of non-wood material.

In the representative composite assembly 76 of FIG. 9, the combinedlength of the elongated layers 78, 80, 82 is substantially equal. Forexample, each layer 78, 80, 82 has a total length of twenty feet with awidth of six inches and a depth of two inches. Layer 78 has an upperelongated portion 84 which is twelve feet in length, and a lowerelongated portion 86 which is eight feet in length. Layer 80 has anupper elongated portion 84 and a lower elongated portion 86 which areeach ten feet in length. Layer 82 has an upper elongated portion 84which is fourteen feet in length, and a lower elongated portion 86 whichis six feet in length. In this example, the joints 88 secured by theconnectors 10 are staggered which promotes strength in the fullyconstructed composite assembly 76. Additional configurations anddimensions of the composite assembly 76 are envisioned by thedisclosure. For example, one or more of the layers 78, 80, 82 may beelongated in a single elongated member constructed of plastic or anothernon-wood material throughout its length. At least two of the elongatedlayers 78, 80, 82 have upper elongated portions 84 comprised of wood,and lower elongated portions 86 comprised of a non-wood material.

FIGS. 11-15 illustrate a further embodiment of a composite assembly 94such as may be used as a vertical support column in a buildingstructure. The building structure may be a residential, commercial, orindustrial building structure. The composite assembly 94 is comprised ofa series of opposing elongated layers 96, 98, 100 joined togetherlengthwise thereof. Each of the layers 96, 98, 100 includes an upperelongated portion in the form of an elongated member 102 which istypically constructed of a first material comprised of wood, such asuntreated wood. The upper elongated portions 102 together collectivelyform an upper assembly 104. Top ends of the upper elongated portions 102are typically used for supporting a superstructure of a building.

The composite assembly 94 also includes a unitary lower assembly 106having a flat lower end 107 embedded securely beneath the ground surfaceG. The lower assembly 106 is constructed of a second material which is anon-wood material such as plastic, although other non-wood materialsbesides plastic may be used. The lower assembly 106 has a central region108 which is provided with reinforcing structure in the form of a pairof spaced apart reinforcing rods 110 as best seen in FIGS. 13 and 14.The rods 110 are typically embodied as rebar constructed of one-halfinch diameter steel which extend longitudinally through the centralregion 108 of the lower assembly 106 from a flat upper end 111 thereofto and beneath the flat lower end 107 thereof for embedding in theground. Each of the rods 110 is preferably formed with bends 112extending inwardly a similar distance, exemplarily one foot, from theupper and lower ends 111, 107, respectively, of the lower assembly 106to facilitate the securement of the rods 110 within the lower assembly106 such as during formation of a plastic or other non-wood lowerassembly 106. In an exemplary embodiment wherein the lower assembly 106is a plastic composite material, the lower assembly 106 may be cast ormolded around the rods 110. In such embodiments, the bends 112 mayfunction to keep the rods 110 from separating from the lower assembly106 during use.

In an exemplary embodiment, the reinforcing rods 110 further extend outfrom the lower end 107 in projections 109. The projections 109 mayexemplarily bend or angle away from one another and the generallyparallel orientation of the reinforced rods 110 when extending throughthe lower assembly 106. In an embodiment, the projections 109 extend ina generally perpendicular direction from the rest of the reinforcing rod110 and extend in such direction beyond a width of the lower assembly106. As depicted in FIG. 11, the lower assembly 106 may be securedwithin a footing F beneath the ground surface G. In an example, thefooting F is a poured concrete footing. The projections 109 extend intothe footing F and further facilitate to secure the lower end 107 of thelower assembly 106 in position beneath the ground G.

At least two of the elongated layers 96, 98, 100 have upper elongatedportions 102 comprised of wood, and the lower assembly 106 comprised ofa non-wood material, such as a solid plastic core.

The upper elongated portions 102 and various height portions of thelower assembly 106 are joined together in an end-to-end relationship atjoints 114, 116, 118 by connector arrangements formed by respectivepairs of connector plates 120, 122, splice plates 124, 126 anddeflection plates 128, 130. The joints 114, 116, 118 are staggered inheight relative to one another as in the composite assembly 76 of FIGS.9 and 10 to promote strength in the composite assembly 94. The joint 114is formed between a flat lower end 132 of the upper elongated portion102 of layer 98 and the flat upper end 111 of the central region 108 ofthe lower assembly 106. The joint 116 is formed between a flat lower end134 of the upper elongated portion 102 of layer 96 and an inwardlyextending ledge 136 formed on the lower assembly 106. The joint 118 isformed between a flat lower end 138 of the upper elongated portion 102of the layer 100 and an inwardly extending ledge 140 of the lowerassembly 106.

The plates 120, 122 define a first plate structure, take the form ofdual-sided connectors 10 as described above and are used to join theelongated layers 96, 98, 100 along opposed interior faces thereof. Inthe examples shown, each of the plates 120, 122 have equal lengths withthe plates 120, 122 lying parallel to each other and with their upperand lower ends in staggered relationship relative to one another. Theplate 120 and plate 122 extend the lengths of respective sides of thecentral region 108, the joint 114 continue along the elongated layer 98.Elongated layer 96 is secured to the plate 120. Elongated layer 100 issecured to the plate 122. As best depicted in FIG. 12, the plate 120 ispositioned across the joint 114 and has a lower end 142 which extends toand terminates at the joint 116. It is to be recognized that inalternative embodiments, the plate 120 terminates shortly before thejoint 116. The plate 122 is positioned across the joint 114 and has alower end 144 which extends to and terminates at the joint 118. It is tobe recognized that in alternative embodiments, the plate 122 terminatesshortly before the joint 118.

The splice plates 124, 126 define a second plate structure and arepreferably configured with single-sided connectors formed with teeth 146only on an inwardly facing surface of a base plate 147. The plates 124,126 are of equal length, lie parallel to one another and have upper andlower ends which are in staggered relationship relative to one another.The plate 124 is centered lengthwise across the joint 116 along exteriorside faces of the layer 96 and the lower assembly 106. A screw fastener148 is passed through an upper end of the plate 124, the layer 96 andthe plate 120, and is secured in the central region 108 of the lowerassembly 106 to anchor the plate 124 on the composite assembly 94 suchthat the teeth 146 penetrate the exterior side faces of the layer 96 andthe lower assembly 106 above and below the joint 116. This furtherserves to secure the flat lower end 138 to the lower assembly 106, andparticularly to the central region 108. The plate 126 is centeredlengthwise across the joint 118 along exterior side faces of the layer100 and the lower assembly 106. A screw fastener 150 is passed throughthe plate 126, the layer 100 and the plate 122, and is secured in thecentral region 108 of the lower assembly 106 beneath the joint 116.Another screw fastener 152 is passed beneath screw fastener 150 throughthe plate 126, the layer 100 and the plate 122, and is secured in thecentral region 108 of the lower assembly 106. The screw fasteners 150,152 fix the plate 126 on the composite assembly 94 such that the teeth146 penetrate the exterior side surfaces of the layer 100 and the lowerassembly 106 above and below joint 118. This further serves to securethe lower end 134 of the upper elongated portion 102 to the lowerassembly 106, and particularly to the central region.

The deflection plates 128, 130 as best seen in FIG. 14 define a thirdplate structure. The deflection plates 128, 130 are similar tosingle-sided connector plates 124, 126 and are formed with teeth similarto teeth 146 on only an inwardly facing surface of the plates 128, 130.The plates 128, 130 are exemplarily of equal length and lie parallel toone another. Embodiments of the deflection plates 128, 120 haverespective upper and lower ends as well as side edges which are alignedwith one another. The plates 128, 130 are both centered lengthwiseacross the joint 118, and are suitably fixed such as by applying asuitable force causing the teeth to be retained in the front and backsurfaces of the layers 96, 100 and the lower assembly 106. In theexample shown, the upper ends of the plates 128, 130 extend above thejoint 116, and the lower ends of the plates 128, 130 extend beneath thejoint 118. The width of the plates 128, 130 extend substantially acrossthe width of the composite assembly 94.

FIGS. 16-19 depict a still further embodiment of a lower assembly 160 asmay be used in connection with embodiments of the assemblies aspresently disclosed. It will be recognized that like reference numeralsare used in FIGS. 16-19 as in other previously described figures todenote like structures. This is done for the purpose of conciseness andto highlight features shown in FIGS. 16-19. It will be recognized thatvarious combinations of features of the embodiments as disclosed in thepresent application may be used while remaining within the scope of thepresent disclosure. In an exemplary embodiment, at least a portion ofthe lower assembly 160 includes at least four reinforcing rods 162. Asbest depicted in FIGS. 16, 17, and 19 in an area between the lower end107 and the upper end 111, and particularly below ledges 136 and 140,two reinforcement rods 162 angle away from the center of the lowerassembly 160 and run parallel to one another along a portion of thelength of the lower assembly 160. In an exemplary embodiment, the centerof the lower assembly 160 is approximated by the center region 108. Inan exemplary manufacture of an exemplary embodiment as disclosed herein,the plastic and/or composite material of the lower assembly 160 mayexemplarily be cast or molded about the reinforcing rods 162.

FIG. 17 is an enlarged view of a portion of FIG. 16 as denoted by line17-17 in FIG. 16. In FIG. 17, the reinforcing rods 162 angle away from arod upper portion 164, which is exemplarily aligned along a center ofthe lower assembly 160 and center region 108. In the embodimentdepicted, the reinforcing rods 162 angle away at a 45 degree angle.However, it will be recognized that this angle may be within a varietyof other angles including 20 degrees, 70 degrees or other anglestherebetween. Additionally the angles may be between 10-80 degrees orother angles. In one embodiment, one of the reinforcing rods 162 is anelongated rod 166 that extends the entire length of the lower assembly160, and may exemplarily end at the lower end in the projections 109.The elongated rods 166 thus make up the upper rod portion 164. A supportrod 168 connected at connecting points 170, which may exemplarily be endwelds, to the elongated rod 166 and extend within at least a portion ofthe lower assembly 160. The support rod 168 may end at connection point170 at a lower portion 172 of the elongated rod 166. FIG. 18 is asectional view taken along line 19-19 and depicts the two reinforcingrods 162 extending within the center region 108. FIG. 19 is a sectionalview taken along line 19-19 and depicts four reinforcing rods 162extending within the lower assembly 160. In an exemplary embodiment, thereinforcing rods 162 as depicted in FIG. 19 may be located ¾ inch fromthe exterior sides of the lower assembly 160, although this is notintended to be limiting. In still further embodiments, one or more ofthe reinforcing rods 162 may include one or more bends (not depicted)such as exemplarily depicted in FIG. 13 and described above. In anotherembodiment (not depicted), both rods continue through the center regionas a rod pair. In a still further embodiment, all four of thereinforcing rods may extend as projections 109 out from the lower end107.

FIG. 20 depicts an embodiment of the unitary lower assembly 106 a havingmultiple reinforcing rods 110, including center reinforcing rods 110 aand side reinforcing rods 110 b. One or more center reinforcing rods 110a extend longitudinally along the central region 108 of the unitarylower assembly 106 a. As depicted in FIGS. 21 and 22, the centerreinforcing rods 110 a may further extend out of the central upper end111 of the central region 108, which can provide further strength at theattachment joint 114 between the lower end 132 of a central layer 98 ofthe upper elongated portion 102. Alternatively or additionally, the oneor more center reinforcing rods 110 may extend out of the flat lower end107 of the unitary lower assembly 106 a in order to form one or moreprojections 109, which can facilitate structural attachment to thefooting F. The central region 108 may be provided with two centerreinforcing rods 110 a extending the length of the center region 108 andconnected by a center plate 123 between the two center reinforcing rods110 a. For example, the center plate 123 may be comprised of metal andmay be welded to the center reinforcing rods 110 a, which mayexemplarily be constructed of rebar, such as one-half inch diametersteel rods.

In accordance with the description above, the unitary lower assembly 106a may be provided with two side regions 115 and 117 on either side ofthe central region 108. An upper end of each of the side regions 115 and117 may terminate in a flat ledge, with side region 115 terminating atledge 136 and side region 117 terminating in ledge 140. The ledges 136and 140 are at a lower position than the central upper end 111, and areat staggered heights with respect to one another, with ledge 136 beingat a higher point than ledge 140, such that the unitary lower assembly106 a has a teared upper end with each region 111, 115, 117 having anupper end terminating at a different height.

The side regions 115, 117 may each be provided with a side reinforcingrod 110 b therein. The side reinforcing rods 110 b may each have anupper end connecting at a rod joint 121 with one of the centerreinforcing rods 110 a. As pictured in FIG. 21, each side region 117 mayhouse two side reinforcing rods 110 b, one extending off of each of thetwo center reinforcing rods 110 a. Accordingly, each center reinforcingrod 110 a has two side reinforcing rods 110 b extending therefrom, oneinto each side region 115, 117. The side reinforcing rods 110 b in theside region 115 may be longer and join with the center reinforcing rod110 a at a higher point than the side reinforcing rods 110 b in theother side region 117. The side reinforcing rods 220 b may extend atapproximately a 90° angle from the rod joint 121 with the centerreinforcing rod 110 a. The side reinforcing rods 110 b may then bend atanother 90° angle such that they generally run parallel with the centerreinforcing rods 110 a.

The side reinforcing rods 110 b may also extend out of the flat lowerend 107 of the unitary lower assembly 106 a in order to form projections109, which may further facilitate connection of the unitary lowerassembly 106 a to the footing F. FIG. 22 demonstrates this arrangement.The side reinforcing rods 110 b may be of any metal or otherconstruction which may provide structural reinforcement to the unitarylower assembly 106 a. In an exemplary embodiment, the side reinforcingrods 110 b may be comprised of rebar, such as one-half inch steel bar.In another embodiment, the side reinforcing rods 110 b may be comprisedof a thinner steel rod than the center reinforcing rods 110 a, such asthe center reinforcing rods 110 a being one-half inch steel rods and theside reinforcing rods 110 b being one-third inch steel rods. FIG. 22depicts the unitary lower assembly 106 a of FIG. 21 joined with theupper assembly 104, which is comprised of upper elongated portions 96,98, and 100. The upper elongated portions, or layers, 96, 98, and 100are connected together via connectors plates 120, 122, as is describedabove. In addition to the connector plates 120, 122, the connectorarrangements which connect the upper assembly 104 and the unitary lowerassembly 106 a further include splice plates 124 and 126, screwfasteners 148 and 149 to fasten the splice plate 124 to the exteriorsite faces of the layer 96 and the unitary lower assembly 120 acrossjoint 116, and screw fasteners 150 and 152 that fasten splice plate 126to the exterior site faces of the layer 100 and the unitary lowerassembly 106 a across joint 118. In the depicted embodiment, screwfasteners 148 and 149 go through the splice plate 26 and the connectorplate 120 to penetrate the central region 108 of the unitary lowerassembly 106 a to engage the center plate 123. Similarly, screwfasteners 150 and 152 go through splice plate 126, elongated layer 100,center region 108, and engage the center plate 123. Thereby, theconnector arrangement engages the center plate 123, which providesadditional stability to the joint of the unitary lower assembly 106 aand the upper assembly 104. As shown in FIG. 22, the connectorarrangement may further include additional screw fasteners 145 thatpenetrate two or more of the elongated portions 96, 98, 100 and theconnector plates 120, 122 there between, and further attach to thecentral region 108 of the unitary lower assembly 106 a. Four additionalscrew fasteners 145 are shown, with two on each lateral side of theupper assembly 104. Each set of two screw fasteners go through arespective elongated portion 96, 100 and penetrate the center ply tonguethat makes up the upper portion of the center region 108 (the portion ofthe center region 108 between the ledge 136 and the central upper end111). In one exemplary embodiment, the screw fasteners 145, 148, 149,150, 152 may be 5/16 inches by 4 inch structural screws.

The upper assembly 104 is made of wood, such as untreated wood, and theunitary lower assembly 106 a is a unitary construction formed of anymaterial other than wood. In one embodiment, the unitary lower assembly106 a is comprised of a solid plastic material or of a composite plasticmaterial. For example, the unitary lower assembly 106 a may be a solidplastic material made of curbside tailings and/or other industrialplastic waste material, which provides a useful application for materialthat would otherwise be discarded in landfills. In one exemplaryembodiment, the solid plastic material is heated and the unitary lowerassembly 106 a is constructed by molding the plastic material around thereinforcing rod(s) 110, such as center reinforcing rods 110 a and sidereinforcing rods 110 b.

FIG. 23 diagrammatically depicts an exemplary embodiment of a compositeassembly 200 positioned within a hole H in the ground G. The compositeassembly 200 includes an upper assembly 214 which is exemplarilyconstructed of a plurality of laminated boards to form a wooden column.The boards of the upper assembly 214 may be secured to one another inthe manner as described above. The composite assembly 200 furtherincludes a lower assembly 216 which is designed for ground contact andis exemplarily constructed of a combination of metal and plastic asdescribed herein.

The lower assembly 216 exemplarily includes a body 228 and an adjustmentleg 218. The adjustment leg 218 is frictionally secured to the body 228at a center hole 242 as described in further detail herein. Theadjustment leg 218 terminates in a foot 220 that is configured to engagethe bottom 222 of the hole H. The foot 220 engages the ground at thebottom 222 of the hole H to support the lower assembly 216 while afooting F, exemplarily concrete, is poured around at least a portion ofthe lower assembly 216. Support rods 226 which are exemplarily steelrebar, extend out of the bottom of the body 228 of the lower assembly216. The support rods 226 may be bent into projections 230 which furtherare surrounded by the footing F which improves securement of the lowerassembly 216 to the footing F. The footing F may be poured to any heightalong the lower assembly 216 and in embodiments wherein the footing Fstops short of the ground level, the remaining portion of the hole 212may be filled in with gravel and/or dirt.

In an exemplary embodiment, the body 228 is constructed of a plasticmaterial. In a still further exemplary and non-limiting embodiment, thebody 228 is constructed of high molecular weight polypropylene (HMWPE).In another exemplary and non-limiting embodiment, the body 228 isconstructed with at least 66% polypropylene (PP) and at least 9% lowdensity polyethelyene (LDPE). A still further exemplary embodiment mayinclude 15% fiberglass shorts and/or 1% color added to the mixture. Inexemplary embodiments, this may include some or all the body 228 beingconstructed of recycled plastic.

In a still further embodiment, at least a portion of the lower assembly216 comprises wood. In such an embodiment, the lower assembly may beconstructed of a plurality of elongated layers for example with the body228 as a center layer sandwiched between two opposed wooden boards. Inanother exemplary embodiment, the body 228 may be a plastic insertinserted into a wooden lower assembly, the insert comprising the centerhole within which the adjustment leg 218 is frictionally held asdescribed in further detail herein. In a still further exemplaryembodiment, the body 228 may be a plastic insert secured to the interiorof a concrete lower assembly, the plastic insert also comprising thecenter hold as described herein within which the adjustment leg 218 isfrictionally held.

FIG. 24 is a perspective view of an exemplary embodiment of the lowerassembly 216, depicting the body 228, which is exemplarily constructedof plastic, in phantom. In an exemplary embodiment, the connectionbracket 234 includes connection blades 238, bottom plate 232, supportrods 226, and support plates 236. The connection bracket 234 isassembled exemplarily by welding. The support rods 226 are secured,exemplarily by welding to the bottom plate 232 of the connection bracket234. The support rods 226 extend along the length of the body 228 toexit the body 228 at the lower end thereof.

The support plates 236 extend between adjacent support rods 226.Exemplarily, the support plates 236 are arranged in a direction parallelto the wooden boards of the upper assembly 214, as well as to theconnection blades 238 of the connection bracket 234, as will bedescribed in further detail herein. In a still further exemplaryembodiment, the support plates 236 and support rods 226 may bepositioned radially interior or exterior of the connection blades 238from the center hole 242. While in other embodiments, the support plates236 and support rods 226 are aligned with the connection blades 238. Inthe embodiment depicted in FIGS. 24 and 25, the support rods 226 and thesupport plates 236 are positioned radially outward from the center hole242 or in the direction towards the exterior of the body 228 from theconnection blades 238. Holes 240 through the support plates 236 help tofacilitate connection between the column 228 and the support plates 236by providing a space through which the plastic material of the body 228can flow and extend. This helps the manufacturing process (e.g.injection molding) of the lower assembly by providing a path for theplastic around and through the support plates 236. Also, when hardened,the plastic through the support plates 236 further secures the body 228and the support plates 236 and support rods 226 together. Material ofthe body 228 extending through the holes 240 in the support plates 236thus helps to improve the connection between the plastic body 228 andthe metal insert of the connection bracket 234.

The body 228 further includes center hole 242 that exemplarily extendsalong the entire length of the body 228. In an embodiment, the centerhole 242 is cast or molded into the column 228 while in anotherembodiment, the center hole 242 may be machined into the column as aseparate manufacturing step. The center hole 242 is exemplarily smallerin diameter than the adjustment leg 218. Due to the difference indiameter, the adjustment leg 218 can be positioned within the centerhole 242 and held in that position by a friction fit between thematerial of the body 28 and the adjustment leg 218. In an exemplaryembodiment, the exterior of the adjustment leg 218 may further includeribbing and/or surface texture facilitates friction fit between theadjustment leg 218 and the material of the body 228 within which thecenter hole 242 is formed. Additionally, a plastic, malleable,deformable, or resilient property of the material of body 228 furtherincreases the friction between the body 228 and the adjustment leg 218.

The friction fit between the body 228 and the adjustment leg 218 isexemplarily strong enough to support the weight of the entire lowerassembly 216 such that the adjustment leg 218 can be moved to a desiredposition between the bottom plate 232 of the connection bracket 234 andthe foot 220. In an exemplary and non-limiting embodiment, the body 228may be 48 includes long and the adjustment leg 24 includes long.Therefore, exemplary embodiment may be adjustable for example between 54includes and 66 inches while other embodiments may be dimensioned to beadjustable along other ranges. When the lower assembly 216 is positionedin the hole, the foot 220 engages the ground at the bottom of the holeand the bottom plate 232 of the connection bracket 234 is located at thepredetermined position above the foot 220 established by the frictionfit between the adjustment leg 218 and the body 228. The friction fitbetween the adjustment leg 218 and the column 228 is further strongenough to support the lower assembly 216, and in particular to supportthe connection bracket 234 and body 228, from moving downward into theholw, while the footing F is poured and set, cured, or partially curedabout at least a portion of the lower assembly 216. In an exemplaryembodiment, the footing F extends upwards to cover the projections 230.In another exemplary embodiment, the footing 224 extends upwards tocover at least a portion of the body 228.

In an exemplary embodiment, the center hole 242 is further tapered alongits length to facilitate ease of insertion of the adjustment leg 218into the center hole 242, and to further increase the friction fit asthe adjustment leg 218 is inserted further into the center hole 242. Ina merely exemplary and non-limiting embodiment, the center hole 242 maytaper from a dimension nominally equal to or greater than the diameterof the adjustment leg 218 at the lower end of the body 228 to a diameterexemplarily 75 percent or less of that of the diameter of the adjustmentleg 218 at the upper end of the body 228. In a still further embodiment,the center hole 242 only tapers along half of the length of the body 228or less. This has been found to help to ease insertion of the adjustmentleg 218 into the center hole 242 without adversely impacting thefriction fit. In a further exemplary and non-limiting embodiment, thecenter hole 242 may be ¾″ diameter at the bottom of the body 228. Thecenter hole 242 may taper over the first four inches of the center hole242 to a diameter of 11/16″, and further tapers to 21/32″ at a distanceof sixteen inches from the bottom of the body 228. It will further berecognized that in an embodiment, the dimension above may be nominaldimensions fro initial casing or molding of the body, while as thematerial of the body cures and hardens (in the example of injectionmolding) the effective diameter of the center hold 242 may shrink fromthese dimensions. In an embodiment, the adjustment leg 218 has a nominalsize of ⅝″ diameter steel rod; however, the steel rod may includeribbing that extends the effective diameter of the adjustment leg. Instill further embodiments, the diameter of the adjustment leg 218 and/orcenter hold 242 (including tapered regions) may be selected to providethe friction fit as described herein. The larger diameter of the centerhole 242 at the bottom of the body 228 facilitates dry inserting theadjustment leg into the center hole 242 before applying a force to thebottom end (e.g. at the foot plate 220) to position the adjustment leginto the body 228.

In a still further exemplary embodiment, the bottom plate 232 furtherincludes a hole 244 in alignment with the center hole 242. In anexemplary embodiment, the adjustment leg 218 is inserted into the lowerend of the body 228. Installation personnel may decrease the distancebetween the foot 220 and the bottom plate 232 by applying a force (e.g.with a hammer) to the foot 220 to move the adjustment leg into the hole242 through the body 228. In adjusting the lower assembly 216 thedistance between the bottom pate 232 and the foot 220 may be increasedby inserting a rod (not depicted) through the hole 244 into the centerhole 242 at the top of the body 228 to engage a top end of theadjustment leg 218. A force applied to this rod will push the adjustmentleg 218 out of the column 228, increasing the distance between thebottom plate 232 and the foot 220. In exemplary embodiments, it has beendiscovered that this adjustment may occur at least more than once whilemaintaining the structural integrity of the friction fit between theadjustment leg 218 and the body 228.

As best depicted in FIG. 26 and with further reference to FIG. 23, theconnection bracket 234 facilitates the connection between the lowerassembly 216 and the upper assembly 214. As previously noted, the upperassembly 214 may be a wooden column formed of a plurality of laminatedboards 246. The laminated boards 246 are secured to the connectionbracket 234 by the connection blades 238. The connection blades 238 areconfigured to extend between the laminated boards 246 of the upperassembly 214. In an exemplary embodiment, grooves are cut through thelaminated boards at the interface between adjacent laminated boards inthe dimension of the connection blades 238. In an exemplary embodiment,the connection blades 238 may be 14 inches long and ⅜ of an inch thick.These connection blades 38 may extend the entire nominal width of theboards of the upper assembly 216, or in embodiments may extend beyondthe widths of the boards. The boards of the upper assembly 216 aresecured to the connection bracket 234 by a combination of bolts orscrews which extend respectively through the boards of the upperassembly and through the connection blades 238 at pre-located anddrilled holes 248. The boards of the upper assembly are positioned suchthat the respective ends of the boards abut the bottom plate 232. Lips250 extend from the bottom plates 232 exterior of the connection blades238. The lips 250 engage the lower assembly 216 along the bottoms of thenarrow faces of the boards of the upper assembly and further help tosecure the upper assembly 214 to the lower assembly 216. It will berecognized that other forms of connection may be used on otherembodiments while remaining within the scope of the present disclosure.

FIG. 26 is a perspective view of a still further exemplary embodiment ofa connection bracket 252. It will be recognized that the connectionbracket 252 includes some similar features as depicted and describedabove with respect to connection bracket 234 in FIGS. 23-25. Likereference numerals are used in the description herein to referencesimilar features between the two exemplary embodiments. The connectionbracket 252 is exemplarily constructed of connection plates 252, abottom plate 254, and the support rods 226. FIG. 27 is a detaileddepiction of an exemplary embodiment of a connection plate 252 and FIGS.28A and 28B are detailed depictions of an exemplary embodiment of thebottom plate 254.

The connection plate 252 includes the connection blade 256 and thesupport plate 258. In the embodiment depicted, the connection blade 256and the support plate 258 are a unitary piece. Exemplarily, theconnection blade 256 is constructed of steel. The connection plates 252extend through slots 260 through the bottom plate 254 and areexemplarily secured thereto by welds 262. Thus, in part because of theirunitary construction in the connection plate 252, the connection blade256 and the support plate 258 are co-linear across the bottom plate 254.

The connection plates 252 further include a transition 264 whichexemplarily tapers the connection plate 252 from the width of theconnection blade 256 to the width of the support plate 258. Aspreviously noted, embodiments of the connection blades 256 areexemplarily the nominal width of the wooden boards (not depicted) towhich the connection blades 256 are secured. The support plate 258 isnarrower such that the support plate 258 is entirely within the body(see e.g. body 228 in FIG. 24). In FIGS. 26 and 27, the transition 264is depicted as extending below (e.g. towards the support plate 258) thebottom plate 254. In an additional exemplary embodiment, the transition264 may be located above the bottom plate 254, or may extend through thebottom plate 254 with a portion of the transition 264 on either side ofthe bottom plate 254. It will be recognized that a dimension of theslots 260 through the bottom plate 254 may be predetermined based upon awidth dimension of the connection plate 252 where it is connected to thebottom plate 254.

Support rods 226 are connected to the bottom plate 254 and to thesupport plates 258, exemplarily by welds 266. In an exemplaryembodiment, the support rods 226 are connected to outer surfaces 268 ofthe support plates 258. By locating and connecting the support rods 226in this position, the support rods 228 are located apart from oneanother and towards the exterior of the body (e.g. body 228 in FIG. 24).This position of the support rods 228 improves their reinforcingfunction of the body, while also distancing them from the center hole(e.g. center hole 242 in FIG. 24) as described above.

FIGS. 28A and 28B depict an exemplary embodiment of the bottom plate254. In particular, FIGS. 28A and 28B show the slots 260 through thebottom plate 254 and the hole 244 which, when the lower assembly 216 isassembled aligns with center hole 242. FIG. 28A is a perspective view ofthe bottom plate 254. FIG. 28B is top view of the bottom plate 254 as itexemplarily appears during construction. In an embodiment, the bottomplate 254 is constructed of a sheet of metal in which the hole 244 andthe slots 260 are cut. Then the lips 250 are formed by bending the metalat bends 270. In an exemplary embodiment, the slots 260 are aligned withthe bends 270 to terminate at the bend 270 and the start of the lip 250.Thus, in an exemplary embodiment, the lips 250 are positioned directlyexterior of the connection plates 252 when the connection bracket 234 isassembled.

This written description uses examples to disclose various embodimentsincluding the best mode, and also to enable any person skilled in theart to make and use these embodiments. The patentable scope is definedby the claims and may extend to include other examples not explicitlylisted that occur to those skilled in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differ from the literal language of the claim, orif they include equivalent elements with insubstantial differences fromthe literal languages of the claims. FIGS. 20-22 illustrate anotherembodiment of a composite assembly having a unitary lower assembly 106,such as may be made of a plastic material. FIGS. 23-28 depict stillfurther embodiments of a composite assembly, and particularly a lowerassembly 200 for use in a composite assembly. Various alternatives andembodiments are contemplated as being within the scope of the followingclaims, particularly pointing out and distinctly claiming the subjectmatter of the present disclosure.

The invention claimed is:
 1. A composite assembly adapted for use in abuilding structure, the composite assembly comprising: a lower assemblycomprising a connection bracket comprising: a bottom plate having first,second, third, and fourth edges; and first and second connection bladessecured to the bottom plate and extending away from the bottom plate,the first and second connection blades extending between the first andsecond edges and positioned interior of the third and fourth edges; andan upper assembly comprising: a first elongated layer comprising a firstelongated member and a second elongated layer comprising a secondelongated member, wherein the first and second elongated members aresecured to each other along respective lengthwise faces of the first andsecond elongated members; a first dual sided connector arranged betweenthe first elongated member and the second elongated member such that thefirst dual sided connector simultaneously engages the first elongatedmember and the second elongated member and the first dual sidedconnector comprises: a unitary base plate having a first surface and asecond surface; first and second tooth pairs extending outwardly fromthe first surface of the base plate, the first and second tooth pairseach comprising a first tooth and a second tooth, the first tooth andthe second tooth each having an axis perpendicular to the first surfaceof the base plate, the first tooth being twisted about the axis of thefirst tooth and the second tooth being twisted about the axis of thesecond tooth; and third and fourth tooth pairs extending outwardly fromthe second surface of the base plate, the third and fourth tooth pairseach comprising a third tooth and a fourth tooth, the third tooth andthe fourth tooth each having an axis perpendicular to the second surfaceof the base plate, the third tooth being twisted about the axis of thethird tooth and the fourth tooth being twisted about the axis of thefourth tooth.
 2. The composite assembly of claim 1, wherein the upperassembly further comprises: a third elongated layer comprising a thirdelongated member wherein the third elongated member is secured to thesecond elongated member along respective lengthwise faces of the secondand third elongated members; and a second dual sided connector arrangedbetween the second elongated member and the third elongated member suchthat the second dual sided connector simultaneously engages the secondelongated member and the third elongated member and the second dualsided connector comprises: a unitary base plate, of the second dualsided connector, having a first surface and a second surface; first andsecond tooth pairs, of the second dual sided connector, extendingoutwardly from the first surface of the base plate, the first and secondtooth pairs each comprising a first tooth and a second tooth, the firsttooth and the second tooth each having an axis perpendicular to thefirst surface of the base plate, the first tooth being twisted about theaxis of the first tooth and the second tooth being twisted about theaxis of the second tooth; and third and fourth tooth pairs, of thesecond dual sided connector, extending outwardly from the second surfaceof the base plate, the third and fourth tooth pairs each comprising athird tooth and a fourth tooth, the third tooth and the fourth tootheach having an axis perpendicular to the second surface of the baseplate, the third tooth being twisted about the axis of the third toothand the fourth tooth being twisted about the axis of the fourth tooth.3. The composite assembly of claim 2 wherein the second elongated layercomprises a fourth elongated member arranged end to end with the secondelongated member to form a joint, the first dual sided connector securesacross the joint into the first, second, and fourth elongated members,and the second dual sided connector secures across the joint into thesecond, third, and fourth elongated members.
 4. The composite assemblyof claim 2, wherein the first connection blade is secured between thefirst and second elongated members and the second connection blade issecured between the second and third elongated members.
 5. The compositeassembly of claim 1, wherein the lower assembly further comprises firstand second lips extending from the first edge and the second edge in thesame direction as the connection blades, wherein the first and secondlips are arranged perpendicular to the first and second connectionblades.
 6. The composite assembly of claim 1, wherein the lower assemblyfurther comprises first and second support plates secured to the bottomplate and extending away from the bottom plate in a direction oppositethe first and second connection blades.
 7. The composite assembly ofclaim 6, wherein the lower assembly further comprises a plurality ofsupport rods extending from the bottom plate, each support rod securedto at least one of the first or second support plates, the support rodsextending away from the bottom plate past the first and second supportplates.
 8. The composite assembly of claim 6, wherein the lower assemblyfurther comprises a hole through the bottom plate, the hole locatedcentrally interior of the first and second connection blades and thefirst and second support plates.
 9. The composite assembly of claim 8,wherein the lower assembly further comprises a body comprising plasticextending away from the bottom plate and extending away from the bottomplate in a direction opposite the first and second connection blades,the body comprising a hole in axial alignment with the hole through thebottom plate, and further comprising an adjustment leg comprising a rodand a foot, the rod of the adjustment leg connected to the lowerassembly within the hole through the body.
 10. The composite assembly ofclaim 1, wherein the lower assembly further comprises a body comprisingplastic extending away from the bottom plate and extending away from thebottom plate in a direction opposite the first and second connectionblades.
 11. The composite assembly of claim 10, wherein the lowerassembly further comprises: first and second support plates secured tothe bottom plate and extending away from the bottom plate in a directionopposite the first and second connection blades; and a plurality ofsupport rods extending from the bottom plate, each support rod securedto at least one of the first or second support plates, the support rodsextending away from the bottom plate past the first and second supportplates; wherein the body is formed about the support plates and at leasta portion of the support rods.
 12. A method of constructing a buildingstructure with a composite assembly adapted for use as a verticalsupport column, the method comprising: providing a lower assemblycomprising: a connection bracket comprising a bottom plate having first,second, third, and fourth edges, the connection bracket furthercomprising first and second connection blades secured to the bottomplate edges and extending away from the bottom plate, the first andsecond connection blades extending between the first and second edgesand positioned interior of the third and fourth edge; a plurality ofsupport rods extending away from the bottom plate; and a body comprisingplastic formed about at least a portion of the support rods of theplurality of support rods, the body extending away from the bottom platein a direction opposite the first and second connection blades;inserting at least a portion of the lower assembly into a hole; forminga footing about at least a portion of the lower assembly; and securingan upper assembly to the first and second connection blades, the upperassembly comprising: a first elongated layer comprising a firstelongated member and a second elongated layer comprising a secondelongated member, wherein the first and second elongated members aresecured to each other along respective lengthwise faces of the first andsecond elongated members, and a first dual sided connector arrangedbetween the first elongated member and the second elongated member suchthat the first dual sided connector simultaneously engages the firstelongated member and the second elongated member, the first dual sidedconnector comprising: a unitary base plate having a first surface and asecond surface; first and second tooth pairs extending outwardly fromthe first surface of the base plate, the first and second tooth pairseach comprising a first tooth and a second tooth, the first tooth andthe second tooth each having an axis perpendicular to the first surfaceof the base plate, the first tooth being twisted about the axis of thefirst tooth and the second tooth being twisted about the axis of thesecond tooth; and third and fourth tooth pairs extending outwardly fromthe second surface of the base plate, the third and fourth tooth pairseach comprising a third tooth and a fourth tooth, the third tooth andthe fourth tooth each having an axis perpendicular to the second surfaceof the base plate, the third tooth being twisted about the axis of thethird tooth and the fourth tooth being twisted about the axis of thefourth tooth.
 13. The method of claim 12, further comprising: applying acompressive force to the first and second elongated members; andpressing the first and second tooth pairs into the first elongatedmember and the third and fourth tooth pairs into the second elongatedmember to secure the first elongated member to the second elongatedmember.
 14. The method of claim 13, wherein the first and secondelongated members are wood.
 15. The method of claim 12, wherein theupper assembly further comprises: a third elongated layer comprising athird elongated member wherein the third elongated member is secured tothe second elongated member along respective lengthwise faces of thesecond and third elongated members; and a second dual sided connectorarranged between the second elongated member and the third elongatedmember such that the second dual sided connector simultaneously engagesthe second elongated member and the third elongated member and thesecond dual sided connector comprises: a unitary base plate, of thesecond dual sided connector, having a first surface and a secondsurface; first and second tooth pairs, of the second dual sidedconnector, extending outwardly from the first surface of the base plate,the first and second tooth pairs each comprising a first tooth and asecond tooth, the first tooth and the second tooth each having an axisperpendicular to the first surface of the base plate, the first toothbeing twisted about the axis of the first tooth and the second toothbeing twisted about the axis of the second tooth; and third and fourthtooth pairs, of the second dual sided connector, extending outwardlyfrom the second surface of the base plate, the third and fourth toothpairs each comprising a third tooth and a fourth tooth, the third toothand the fourth tooth each having an axis perpendicular to the secondsurface of the base plate, the third tooth being twisted about the axisof the third tooth and the fourth tooth being twisted about the axis ofthe fourth tooth.
 16. The method of claim 15, further comprisingaligning the upper assembly relative to the lower assembly with thefirst connection blade extending between the first and second elongatedmember and the second connection blade extending between the second andthird elongated member.
 17. The method of claim 12 further comprisingfirst and second support plates secured to the bottom plate andextending away from the bottom plate in a direction opposite the firstand second connection blades wherein each support rod is secured to atleast one of the first or second support plates and the support rodsextending away from the bottom plate past the first and second supportplates.
 18. The method of claim 12, wherein the support rods extendexterior of the body and wherein forming the footing about at least aportion of the lower assembly comprises forming the footing aboutportions of the support rods extending exterior of the body.
 19. Themethod of claim 12 wherein the body comprises a center bore extendinglengthwise centrally within the body, the method further comprising:inserting an adjustment leg into the center bore of the body to connectthe adjustment leg to the body, the adjustment leg comprising a foot;placing the foot in contact with a bottom of the hole when the lowerassembly is at least partially inserted into the hole; and forming thefooting about the foot.
 20. The method of claim 12, wherein the supportrods extend exterior of the body and further comprising forming thefooting about portions of the support rods extending exterior of thebody.